MX2013007398A

MX2013007398A - Method of forming elastomeric laminates having targeted elastic properties for use in personal care articles.

Info

Publication number: MX2013007398A
Application number: MX2013007398A
Authority: MX
Inventors: Paul D Beuther; Brian K Rhodes
Original assignee: Kimberly Clark Co
Priority date: 2010-12-29
Filing date: 2011-11-21
Publication date: 2013-09-02
Also published as: EP2658494A4; KR20130133227A; KR101905928B1; AU2011350918A1; US9241838B2; CN103269663A; US8491741B2; WO2012090090A2; US20130284366A1; EP2658494B1; US20120168063A1; RU2013133792A; BR112013016537A2; CO6710955A2; RU2596466C2; BR112013016537B1; EP2658494A2; AU2011350918B2; WO2012090090A3; CN103269663B

Abstract

A method of forming an elastomeric laminate having targeted elastic properties for use in personal care articles is disclosed. In particular embodiments, the method comprises providing first and second nonwoven webs; providing a core layer of elastomeric material under tension; sandwiching the core layer between the first and second nonwoven webs; bonding the core layer to at least one of the first and second nonwoven webs; providing an elastomeric film ribbon web under tension; sandwiching the elastomeric film ribbon web between the first and second nonwoven webs; and fusing the elastomeric film ribbon web to the first and second nonwoven webs. In particular embodiments, the core layer of elastomeric material is an elastomeric film web core layer. In particular embodiments, the elastomeric film ribbon web, the core layer, or both is/are bonded to the first and second nonwoven webs solely by fusing, without the use of adhesive.

Description

PAPA METHOD FORMING ELASTOMERIC LAMINATES THAT HAVE SPECIFIC ELASTIC PROPERTIES TO BE USED IN ARTICLES FOR PERSONAL CARE BACKGROUND Disposable personal care items are commonly used in society, including diapers, underpants, underpants, adult incontinence garments, items for women's hygiene, surgical garments, clothing protective and similar. Frequently, such articles are constructed of polymeric substrates including, for example, polyolefin films and polyolefin nonwovens such as spunbonded materials or carded materials and fabrics. It is commonly desirable to provide such articles with elastic properties, such as through the use of elastic threads or elastic films. It is also commonly desirable to provide such articles in elastic target or localized properties for a specific functionality. For example, it is often desirable to provide elastication on one or more edges of certain articles, such as the waist leg openings of the garments, on the crotch edge and the pads for menstruation or for incontinence, or at the neck or wrist openings of disposable garments, such as surgical or safety gowns or gowns. The conventional approach to providing such elastication has been to adhesively fix rubber-like yarns of elastomeric material to the polymeric substrate. With the release of the tensioning force, the elastic threads pick up the substrate, providing the desired functional properties, such as, for example, providing a comfortable notch around the leg opening or waist opening of a disposable garment.

The conventional approach to elasticity approach requires the use of adhesive to bond the elastic adhesives to the substrate and hold them in place under tension. Such adhesives add cost and process complexity to the manufacture of such articles. In addition, there is a restricted ability to recycle the waste and trim of such a manufacturing process because such cutting waste contains a mixture of polyolefin-substrate components, rubber-like elastic yarns, and adhesive. Therefore, there is a need for an improved method for providing specific or localized elastic properties in disposable personal care articles in need of the adhesive.

SYNTHESIS OF INCORPORATIONS In one aspect, the present invention relates to a method for forming an elastomeric laminate having specific elastic properties for use in personal care articles. The method defines a machine direction and a cross machine direction. In particular embodiments, the method comprises providing the first and second woven fabrics, each defining a width in the transverse direction; providing a core layer of the elastomeric material under tension, the layer not containing a width in the transverse direction of at least 75 percent more than the width of at least one of the first and second nonwoven fabrics; sandwiching the core layer of the elastomeric material between the first and second non-woven fabrics, attaching the core layer of the elastomeric material to at least one of the first and second non-woven fabrics; providing an elastomeric film tape fabric under tension; sandwiching the elastomeric film web between the first and second nonwoven webs; and joining the elastomeric film web fabric to the first and second nonwoven fabrics by fusing the elastomeric film web fabric to the first and second nonwoven webs. In particular embodiments, the elastomeric film ribbon fabric is attached to the first and second nonwoven fabrics only by fusing, without the use of adhesive. In particular embodiments, the core layer of the elastomeric material is a core layer of elastomeric film fabric. In particular embodiments, joining the core layer of the elastomeric material to at least one of the non-woven fabrics first and second comprises fusing the core layer of elastomeric film fabric to at least one of the first and second nonwoven fabrics. In particular embodiments the elastomeric film fabric core layer is joined to at least one of the first and second nonwoven fabrics only by melting, without the use of adhesive.

In another aspect, the present invention relates to a method for manufacturing the garment for personal care, the garment comprises an elastic laminate having specific elastic properties. The method defines a machine direction and a cross machine direction. In particular embodiments, the method comprises providing the first and second nonwoven fabrics, each defining a transverse direction width; providing a core layer of elastomeric material under tension, the core layer having a transverse direction width < of at least 75 percent of that of the width of at least one of the first and second non-tea fabrics; sandwiching the core layer of the elastomeric material between the first and second non-woven fabrics, joining the core layer of elastomeric material to at least one of the first and second non-woven fabrics; providing an elastomeric film tape fabric under tension; sandwiching the elastomeric film web fabric between the first and second woven fabrics; and joining the elastomeric film web fabric to the first and second nonwoven fabrics by fusing the elastomeric film web fabric to the first and second nonwoven webs. In particular embodiments, the personal care garment when worn defines a waist opening and two leg openings, and the elastomeric film web fabric is placed on one side of the waist opening, on one side of one or both of the openings in the two leg openings, or in both the waist opening and the leg openings.

Several embodiments of the present invention can in particular instances provide efficient techniques for the manufacture of elastomeric laminates for use in the construction of personal care articles. In particular embodiments, such techniques eliminate the use of the adhesive in the lamination phase of the process, thereby reducing the material and potentially the cost of capital equipment. In addition, the ease with which waste materials can be recycled can, in certain embodiments, be improved.

DEFINITIONS Within the context of this description, each term below will include the following meaning or meanings. The additional terms are defined in other parts of the description.

"Attached" refers to the union, adhesion, clamping, connection, or the like of two elements. The two elements will be considered to be joined together when they are directly attached to each other or indirectly to one another, such as when each is directly attached to intermediate elements.

"United" refers to the union, adhesion, connection, subjection to similar of two elements. The two elements will be considered to be joined together when they are directly linked to one another or indirectly to each other such as when each is directly linked to intermediate elements.

"Understanding" is inclusive or open-ended and does not exclude additional non-recited method steps or elements.

The term "disposable" refers to items which are designed to be discarded after limited use rather than being washed or otherwise restored for re-use.

The term "arranged", "arranged on" and variations thereof are meant to mean that an element may be integrated with another element, or that an element may be a separate structure attached or placed or placed on another element.

The term "elastic", the term "elasticized", "elasticity" means that property of a material or compound by virtue of which it tends to recover its original size and shape after the removal of the farce that causes a deformation.

"Elastomeric" refers to a non-composite material which can be lengthened by at least one percent of its relaxed length which will be recovered, with the release of the applied force by at least 20 percent of its elongation. It is generally preferred that the elastomeric material or the composite be capable of being elongated by at least 100 percent, more preferably at least 200 percent of its relaxed length and recover, with the release of an applied force, at least 50 times a hundred of its lengthening.

"Fusing", and its derivatives means joining two materials by at least partially fusing one or both of these thermally. The two materials will be considered to be fused together when they are fused, directly to each other or indirectly to one another, such as when each is directly fused to intermediate materials.

; The term "integral" is used to refer to several parts of a single unitary element rather than to separate heights attached to one another or placed one on another or placed close to one another.

"Layers" when used in the singular may have the dual meaning of a single element or a plurality of elements.

These terms may be defined in an additional language in the remaining parts of the description., BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 representatively illustrates a perspective view of an embodiment of an elastomeric laminate manufacturing process embodying the principles of the present invention.

Figure 2 representatively illustrates a perspective view of an alternate embodiment of an elastomeric laminate manufacturing process embodying the principles of the present invention.

Figure 3 representatively illustrates a perspective view of another alternate embodiment of an elastomeric laminate manufacturing process embodying the principles of the present invention.

Figure 4 representatively illustrates a perspective view of another alternate embodiment of an elastomeric laminate manufacturing process embodying the principles of the present invention.

Figure 5 representatively illustrates a perspective view of an embodiment of a garment manufacturing process embodying the principles of the present invention.

Figure 6 representatively illustrates a perspective view of an alternate embodiment of a garment manufacturing process incorporating the principles of the present invention.

Figure 6 representatively illustrates a perspective view of another alternate embodiment of a garment manufacturing process embodying the principles of the present invention.

Figure 8 representatively illustrates a perspective view of another alternate embodiment of a garment manufacturing process embodying the principles of the present invention.

DETAILED DESCRIPTION OF THE EXAMPLE INCORPORATIONS The reference to figures 1-8 will be made to describe several examples which incorporate certain principles of the invention. It should be noted that the embodiments shown in Figures 1-8 are merely representative examples of the invention. When for illustrative purposes certain features of the present invention are described herein and illustrated with respect to a garment manufacturing process in the "transverse direction" the various aspects and embodiments of the present invention are suitable for use with both processes "the direction of the machine "" in the transverse direction to the machine ", and include processes for making such garments as disposable diapers, disposable swim shorts, disposable training pants, disposable enuresis garments, women's care products, surgical garments and similar.

In one aspect, the present invention relates to a method for forming an elastomeric laminate having specific elastic properties for use in personal care articles. Referring to Figures 1-4, the method 10 defines a machine direction 20 and a direction transverse to the machine 21. The method includes providing a first nonwoven fabric 1 defining a width in the transverse direction 3, and a second non-woven fabric 2 defining a width in the transverse direction. The method further comprises providing a core layer of an elastomeric material 5 under tension. The core layer defines a width 6. The core layer can have a series of elastomeric yarns; In this case, the width 6 is the distance in the transverse direction 21 measured between the outer edges of the two outermost edges. Preferably, the core layer 5 is an elastomeric film fabric core layer 5a. In the particular embodiments, the core layer 5 has a width in the transverse direction 6 of at least 75 percent, more particularly of at least 90 percent, and even more particularly of about 100 percent that of at least 1 of the width 3 of the first non-woven fabric 1 and the width 4 of the second non-woven fabric 2.

The method further includes providing an elastomeric film web fabric 7 under tension. The webbing 7 has a width in the transverse direction 8 suitable for providing the desired functionality, such as, for example, about 2.5 centimeters, about 2 centimeters or about 1 centimeter. Elastomeric films suitable for use as either an elastomeric film fabric core layer 5a or as the elastomeric film web tissue 7 are described in the publication of United States of America patent application No. 2008/0076315 , in the publication of the patent application of the United States of America No. 2008 / 00.95978 and in the publication of the patent application of the United States of America No. 2009/0197041, each of which has been assigned to Kimberly Clark Worldwide, Inc., and each of which is incorporated herein by reference to the extent that it is not inconsistent with the present disclosure. In particular embodiments, it may be desirable to produce an "off-line" elastomeric film for one or both of the core layer 5a and the tape layer 7, so that the film can be collected, such as through a roller or reel, and can be delivered and developed within the manufacturing process for the personal care in question. Examples of suitable films are described in the publication of the patent application of the United States of America No. 2008/0076315, in the publication of the patent application of the United States of America No. 2008/0095978, and in Publication of U.S. Patent Application No. 2009/01970 1. It has been found that certain films, such as films based on some of those described in the preceding publications, can be rolled into a roll form. by taking measures to limit the surface tack of the film. In certain embodiments, a film is created which includes a core layer essentially devoid of inorganic matter, placed in the form of a sandwich by one or two layers of film skin, one or both of which include an inorganic material. In a particular example, a film layer for use in conjunction with the present invention includes a core layer composed of 100 percent propylene polymer VISTAMAXX ™ from ExxonMobil of Chemical Co., Houston Texas United States of America placed in the form of sandwich on one or both of the faces or a layer or layers of skin, the skin layer being composed of 30 percent VISTAMAXX ™ propylene polymer and 70 percent inorganic material, such as calcium carbonate (CaC03). The example construction allows the film layer to be collected in the form of a roll, and subsequently to be unrolled into a laminate manufacturing process without undesirably binding the layers on the roll, and still being thermally melted to other layers of the film. laminate, as will be described later.

The method further includes sandwiching the core layer of elastomeric material 5 and 3 the first non-woven fabric 1 and the second non-woven fabric 2, and also sandwiching the elastomeric film belt fabric 7 between the first non-woven fabric 1 and the second non-woven fabric 2. In certain embodiments, such as that shown in Figure 1, the core layer 5 is placed in a side-by-side relationship by the fabric of belt 7, so that the two are not superimposed on each other. In another embodiment, such as that shown in FIGS. 2-4, the core layer 5 is superimposed on the web fabric 7 so that the web fabric 7 is partially or completely overlapped by the core layer 5. For example, in FIG. an embodiment wherein the core layer 5 is an elastomeric film fabric core layer 5a, the elastomeric film fabric core layer 5a may not be superimposed on the elastomeric film tape layer 7 as representatively illustrated in Figure 1, or alternatively, the elastomeric film fabric core layer 5a may be superimposed on the elastomeric film tape layer 7 as representatively illustrated in Figures 2-4. In one embodiment, the elastomeric belt fabric 7 comprises an over-formed part integrally formed of the elastomeric film fabric core layer 5a (not shown). The basis weights of the film web core layer 5a and the film web weave 7 may vary depending on the functional elastic properties desired in the personal care article. In one example, the base weights of the core layer of the film fabric 5a and the film web weave 7 are the same. In another example, these differ by at least 10 percent, and preferably at least 20 percent.

The method in the particular embodiments also includes attaching the core layer of elastomeric material 5 to at least one of the first non-woven fabric 1 and the second non-woven fabric 2. In the particular embodiments, such as those representatively illustrated in FIG. Figure 1, in Figure 2 and Figure 4, the process includes joining the core layer 5.a to both the first non-woven fabric 1 and the second non-woven fabric, such as in the incorporations in which the core is A core layer of elastomeric film 5a. In other embodiments, the core layer 5a is "pre-bonded" to one of the non-woven fabrics, such as the first non-woven fabric 1, in a precursor process. If the material is supplied in such a way (this is supplied to the personal care article manufacturing process in a "half laminated" roll form which one side of the film core layer is made to at least provisionally made match a non-woven fabric, but where the opposite side of the film core layer is not yet matched to the non-woven fabric, and remains exposed), then the process may include attaching the core layer 5a to just one of the first and second nonwoven fabrics 1 and 2.

The method in particular incorporations further includes attaching the elastomeric film web fabric 7 to the first and second nonwoven fabrics 1 and 2 by fusing the elastomeric film web fabric to the first and second nonwoven web, such as through the use of heat, pressure and / or ultrasonic energy. An example, an engraving roll with heated pattern is used to carry out the melting. Desirably, the nature of the film allows it to be attached to non-woven fabrics in the use of adhesive, but merely through the introduction of energy such as heat, pressure, ultrasonic energy. Therefore, in the particular embodiments, the elastomeric film belt fabric 7 is joined to the first and second nonwoven fabrics 1 and 2 only by melting, without the use of adhesives. Examples of such techniques are taught in the 1st publication of the patent application of the United States of America No. 2008/0076315, in the publication of the patent application of the United States of America No. 2008/0095978 and in the publication of the patent application of the United States of America No. 2009/0197041, to which reference has been made above. In the particular embodiments, the film web weave 7 can be directly fused to one or both of the first and second nonwoven fabrics 1/2 as representatively illustrated in FIG. 1. Alternatively, the web of the web 7 it can be fused directly to one of the non-woven fabrics, it can still be indirectly fused to the other non-woven fabric by being directly and intermediately fused to the core layer 5 or another layer, as representatively illustrated in FIGS. -4.

And the core layer of elastomeric material 5 is a fabric core layer of elastomeric film 5a, in the particular embodiments, the joining of the core layer of the elastomeric material to at least one of the first and second non-woven fabrics 1 and 2 includes fusing, the core layer of elastomeric non-woven fabric to at least one of the first and second non-woven fabrics 1 and 2. In one example, an engraving roll with heated pattern is used to carry out the melting . In particular embodiments, the elastomeric film fabric core layer 5a is attached to at least the first and second nonwoven fabrics only by melting without the use of adhesive. Examples of such techniques are taught in the publication of the patent application of the United States of America No. 2008/0076315, in the publication of the patent application of the United States of America No. 2008/0095978 and in the publication of the patent application of the United States of America No. 2009/0197041, mentioned above. For example, in particular embodiments, the method includes fusing the core layer of elastomeric film fabric 5a to one or both of the first and second nonwoven fabrics 1 and 2, using heat, pressure and / or ultrasonic energy. In a desirable embodiment, both the elastomeric film fabric core layer 5a and the elastomeric film web fabric 7 are fused either directly or indirectly to the first non-woven fabric 1 and to the second non-woven fabric 2 without the use of adhesive, such as through the use of heat, pressure, and / or ultrasonic energy. The use of such a technique may in particular incorporations result in certain benefits. First, the elimination of the conventional use of receipt to join the layers within the elastomeric laminate reduces the cost of material. The second place, the elimination of the conventional use of adhesive reduces the cost, the maintenance and the delay associated with the equipment of application, of adhesive. Finally, if the material used to form the elastomeric film fabric core layer 5a is the same as or chemically compatible with the material used to form non-woven fabrics 1 and 2, the waste of the entire resulting laminate can be recycled and reused to make new non-woven fabrics, new elastomeric film fabrics, or other materials. In a particular example, the elastomeric film fabric core layer 5 and the elastomeric film web fabric 7 are composed primarily (but not necessarily completely) of the polypropylene, and the non-woven fabrics 1 and 2 are composed first ( but not necessarily in complete form) of polypropylene. Desirably (but optionally), both of the elastomeric film web fabric 7 and the elastomeric film fabric core layer 5a are fused either directly or indirectly, to the first non-woven fabric 1 and to the second woven fabric 2 in the Use of the adhesive in a single operation.

In another aspect, the present invention relates to a method 30 for manufacturing a plurality of disposable absorbent holds 32; in the examples of the method they are representatively illustrated in Figure 5-8. Method 30 builds upon method 10 of forming an elastomeric laminate having specific elastic properties described above. In particular embodiments, the method 30 comprises providing a first non-woven fabric 1, such as an outer cover fabric la, which moves in a machine direction 20. The outer core fabric Ia in the particular embodiments incorporates a front edge 26 and a rear edge 28, both of which extend machine direction 20.

The method 30 in the particular embodiments also includes providing at least a second non-woven fabric 2, such as a pair of nonwoven lining fabrics 2a and 2b. The method 30 further includes providing at least one core layer of the elastomeric material 5 under tension, such as the first core layer 5a and the second core layer 5b. Each core layer 5a and 5b has a width of the transverse direction of at least 75 percent of that of the width of at least one of the first non-woven fabric a and of the second non-woven fabric 2a and 2b. In the examples of Figures 5-8, the core layers 5a and 5b each have a width approaching 100 percent of that of the width of each of the second respective non-woven fabric fabrics 2a and 2b. The method further includes sandwiching each core layer of elastomeric material 5a and 5b between the outer cover fabric and the respective non-woven fabric or lining fabrics 2a and 2b. The method further includes attaching the core layer of elastomeric material 5 to the first non-woven fabric 1, to the second or second non-woven fabrics 2 or both, such as through melting as described above. In particular embodiments, the outer cover fabric may be provided by two separate outer cover fabrics, as in the example of FIG. 7. Such incorporation therefore includes a pair of first non-woven fabrics Ib, le, a pair of second non-woven fabrics 2a and 2b and a pair of cores 5a and 5b.

As described above, particular embodiments, such as those representatively illustrated in Figure 6 and Figure 7, the process includes the joining (e.g., by melting) of the core layer 5a to both the first non-woven fabric the / lb and to the second non-woven fabric 2a / 2b, such as in the constructions in which the core layer- is an elastomeric film core layer 5a / 5b. In these embodiments, each core layer 5 and each non-woven fabric 2 are provided separately, and these are laminated together during the continuous machine manufacture of the garments. For example, as representatively illustrated in Figure 6 and Figure 7, in one embodiment the method includes providing a supply of core roll layer of elastomeric film fabric 5a / 5b and providing a separate supply of rolls of fabric non-woven 2a and 2b. In other embodiments, the core layer 5a / 5b is "pre-bonded" to one of the non-woven fabrics, such as a second non-woven fabric 2, in a precursor process. If the material is supplied in such a way (that is, supplied to the personal care article manufacturing process in a "rolled" pit shape) in which one side of the film core layer has already been matched with a non-woven fabric, but where the opposite side of the film core layer has not been matched with a non-woven fabric, and remains exposed), wherein the process includes attaching the core layer of 5a to the first nonwoven fabric 1, second nonwoven fabric 2 or both. For example, as illustrated representatively in Figure 5 and Figure 8, the method can include providing a single roll supply of elastomeric film laminate 15 (shown in the example, 2 separate supplies the film laminate 15a and 15b), wherein the laminate 15 over the roll supply or supplies comprises at least two layers, one layer making an elastomeric film fabric core layer 5a / 5b and the other layer being a non-woven layer 2a / 2b, to provide a prefabricated "one-sided" elastomeric laminate 15a / 15b. Note that in Figure 15 and Figure 18, the individual layers of elastomeric film laminate 15 are not shown, but instead the laminate is shown as a unique "prefabricated" laminate substrate.

To the embodiments of Figures 5-8, the outer cover fabric is (and in the case of Figure 7, the Ib fabric), the non-woven fabrics 2a and 2b and the core layers of the elastomeric material 5a and 5b. collectively they define a composite garment fabric 110. (Note that in the example of Figure 7, the composite garment fabric 110 is defined by two composite garment fabric portions 110a and 110b). The method 30 in the particular appendages further includes providing a supply 158 of individual absorbent assemblies 58, superimposing the individual absorbent assemblies 58 on the composite garment fabric 110, and attaching the individual absorbent assemblies 58 to the composite garment fabric 110. In certain Embodiments, such as those representatively illustrated in Figures 5-8, absorbent assemblies can be manufactured in one orientation, and then cut and rotated 90 degrees (such as in a cutting and rotating station 159) prior to attachment gone, of composite garment 110. The method can in particular embodiments also include, remove the portions 105 of the composite garment fabric 110 (such as in cutting stations 108) to define a series of spaced and spaced holes 106, referring to thus in the composite garment fabric 110 a series of interconnected 120 of absorbent garments of sechables 32. Such portions 105 can be removed from the outer cover fabric before the non-woven fabrics 2a and 2b and the core layers 5a and 5b are removed to the outer cover fabric (not shown), or can be removed. of the outer cover fabric after the non-woven fabrics 2a and 2b and the core layer 5a and 5b are fastened to the outer cover fabric (as depicted representatively in Figures 5-8). In addition, such parts 105 may be removed from the composite garment fabric 110 before the individual absorbent assemblies 58 are attached to the composite garment fabric 110 (as representatively illustrated in Figures 5-8), or may be removed from the garment fabric. compound 110, after the individual absorbent assemblies 58 are attached to the composite garment fabric (not shown).

The method 30 may further include bending the composite garment fabric 110, such as a garment folding station 112, along a transversely centered longitudinal fold line extending in the machine direction 20, so that the front edge 26 is brought into close proximity with the rear edge 28. In the particular embodiments, the method further comprises creating a series of side seam joints 150 (such as at sewing station 152) spaced apart in the machine direction 20. The method further comprises cutting the composite garment fabric 110 into a series of cutting locations 155 (such as at cutting station 156) spaced apart in the machine direction 20 to create the plurality of disposable absorbent garments.

The method 30 further includes providing at least one tissue of. elastomeric film web 7 under tension, sandwiching the elastomeric film web 7 between two layers of non-woven fabric, such as the first non-woven fabric and the second fabric or the second non-woven fabrics 2 a and 2b, and joining through fusion, directly or indirectly, (as explained above, the elastomeric film web fabric 7 to the first and second non-woven fabrics 1 and 2, preferably without the use of adhesive. the personal care garment defines a waist opening 40 and two leg openings 42. In particular embodiments, the elastomeric film web fabric 7 is placed on one side of the waist opening 40, of the front edge of the legs. leg openings 42 and / or the rear edge of a leg opening 42. For example, in particular embodiments, method 30 includes fastening a continuous back leg elastic band fabric 7a. to the outer cover fabric the / lb or to one of the lining or woven fabrics 2a, 2b. The rear leg elastic band fabric 7a extends or moves predominantly in the machine direction 20. In particular embodiments, as representatively illustrated in Figures 5-8, the method further comprises partially overlapping or completely overlapping the fabric. back leg elastic band fabric 7a with the core layer 5. For example, the method can comprise sandwiching at least a portion of the elastic leg fabric of the rear leg continues 7a between the core layer 5 and the outer cover fabric 1 (figure 5, figure 6 and figure 8), or between the core layer 7 and the nonwoven fabric or fabrics 2 (figure 7). In similar forming, in the particular embodiments, the method 30 also includes attaching a continuous front leg elastic band fabric 7b to the outer jacket tees of the lb or one of the non-woven lining fabrics 2a and 2b. The front leg elastic member 7b extends or moves predominantly in the machine direction 20.

In the particular embodiments, as representatively illustrated in Figures 5-8, the method further comprises partially overlapping or completely overlapping the elastic fabric of the front leg 7b with the core layer 5. For example, the method may comprise sandwiching at least a portion of the front leg elastic band fabric continued 7b between the core layer 5 and the outer cover fabric 1 (figures 5, 6 and 8) or between the core layer 5 and the non-woven fabric or the non-woven fabrics 2 (Figure 7).

In particular embodiments, the method 30 may also include sandwiching the continuous elastic web fabrics 7c and 7d between the fabric or outer cover fabrics a / lb and the non-woven lining fabrics 2a and 2b. In one embodiment, an elastic waistband fabric 7 is placed in the form of a sandwich in a straight line, and the elastic leg fabric is placed in the form of a sandwich in an oscillating arched line (see for example figure 4) . In a variant, such as that representatively illustrated in Figure 8, the method may include folding the edge of one or both of the first non-woven fabric or the second non-woven fabric or fabrics 2a and 2b. For example, in one embodiment, the method includes bending the front edge 26 of the outer cover fabric as such at the front waist band bending station 136, to create a front waist edge fold 127 and to have sandwich form the 7d ribbon fabric inside the fold. In one embodiment, the second non-woven fabric 2d comprises an over-formed part integrally formed of the first non-woven fabric la. The method can instead additionally include bending the edge 128 of the outer cover fabric such as in the rear waist band bending station 138, to create a rear waist edge fold 129 and to have the shape of sandwich the ribbon fabric 7c inside the fold. In such an embodiment, the second non-woven fabric 2c comprises an over-formed part integrally formed of the first non-woven fabric la.

In certain embodiments, the method 30 further comprises at least partially deactivating the elastomeric properties of one or more of the core layers 5, of one or more of the belt fabrics 7, or both, using heat, ultrasonic, pressure or other techniques In more particular embodiments, the parts of both the core layer 5 and the web fabric 7 are deactivated in a single process step, such as through a rotating deactivation device. Examples of the techniques for deactivating the elastic properties in various elastomeric laminates are described in U.S. Patent No. 5,660,657 issued May 5, 1998 to Rájala et al. And assigned to Kimberly-Clark Worldwide, Inc. and they are also described in the 'United States of America patent application No. 12/605, 0 · 92.

In the particular embodiments, various components such as the outer cover fabric, the lining fabrics 2a, 2b, the core fabrics 5a and 5b or the ribbon fabrics 7a, 7b, 7c, 7d can be printed or pigmented to include graphics, texts, color, or other images. Such an impression may occur during the assembly of the garment in conjunction with the currently described method, or may occur prior to such assembly in a pigmentation step or "pre-prepress" off-line.

It will be appreciated that the details of the above embodiments given for purposes of illustration should not be considered as limiting the scope of this invention. When only a few example embodiments of this invention are described in detail, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without departing materially from the novel teachings and advantages of this invention. So, all its modifications are intended to be included "within the scope of the invention, which is defined in the following clauses and all equivalents thereof.In addition, it is recognized that many incorporations can be conceived which do not achieve all the advantages of some incorporations, particularly of the preferred embodiments, but with the absence of a particular advantage should not be considered as necessarily signifying that such incorporation is outside the scope of the present invention.

Claims

R E I V I N D I C A C I O N S

1. A method for forming an elastomeric laminate having specific elastic properties for use in personal care articles, the method defines a machine direction and a cross machine direction, the method comprising: providing the first and second nonwoven fabrics, each defining a width to the transverse direction; providing a core layer of elastomeric material under tension, and said core layer having a width in the transverse direction of at least 75 percent that of the width of at least one of the first and second nonwoven webs; sandwiching said core layer of elastomeric material between the first and second non-woven fabrics, joining the core layer of elastomeric material to at least one of the first and second non-woven fabrics; providing an elastomeric film tape fabric under tension; sandwiching said elastomeric film web fabric between the first and second non-woven fabrics, and joining the elastomeric film web fabric to the first and second non-woven fabrics by fusing elastomeric film web fabric to the first and second non-woven fabrics.

2. The method as claimed in clause 1 characterized in that the elastomeric film web fabric is joined to the first and second non-woven fabrics only by melting, without the use of adhesive.

3. The method as claimed in clauses 1 or 2, characterized in that the core layer of the width of the elastomeric material is at least 90 percent of that of the width of at least one of the non-woven fabrics first and second.

4. The method as claimed in clauses 1, 2 or 3, characterized in that the core layer of the elastomeric material is a woven core layer of elastomeric film.

5. The method as claimed in clause 4, characterized in that the width of the core layer of elastomeric film fabric is at least 90 percent that of the width of at least one of the non-woven fabrics first and second.

6. The method as claimed in clauses 4 or 5, characterized in that the elastomeric film fabric core layer is superimposed on the elastomeric film web fabric.

7. The method as claimed in clauses 4, 5 or 6, characterized in that the joining of the core layer of the elastomeric material to at least one of the first and second non-woven fabrics comprises fusing the core layer of film fabric. elastomeric to said at least one of the first and second non-woven fabrics.

8. The method as claimed in clause 7 characterized in that the elastomeric film fabric core layer is joined to said at least one of the first and second nonwoven fabrics by melting, without the use of adhesive.

9. The method as claimed in clause 8 characterized in that the core layer of elastomeric film fabric is joined to both first and second nonwoven fabrics only by melting, without the use of adhesive.

10. The method as claimed in any of clauses 4-9, characterized in that the elastomeric belt fabric comprises an integrally formed and over-bent portion of the elastomeric film fabric core layer.

11. A method for manufacturing a garment for personal care, the garment comprises an elastomeric laminate having elastic and specific properties, the method defines a machine direction and a cross machine direction, the method comprises: providing the first and second nonwoven fabrics, each defining a width in the transverse direction; providing a core layer of elastomeric material under tension, said core layer having a width in the transverse direction of at least 55 percent that of the width of at least one of the first and second nonwoven webs; sandwiching said core layer of elastomeric material between said first and second nonwoven webs; joining the core layer of the material: elastomeric at least one of the first and second non-woven fabrics; providing a ribbon fabric; elastomeric film under tension; : sandwiching said elastomeric film web fabric between the first and second non-woven fabrics; Y joining the elastomeric film web fabric to the first and second non-woven fabrics by fusing the elastomeric film web fabric to the first and second non-woven fabrics; wherein when cut, the garment; personal care defines a waist opening and two leg openings, and wherein the elastomeric film web fabric is positioned on one side of at least one of the waist opening and of the two leg openings.

12. The method as claimed in clause 11 characterized in that the elastomeric film web fabric is bonded to the first and second nonwoven fabrics only by melting without the use of adhesive.

13. The method as claimed in clauses 11 or 12, characterized in that the core layer of the wide material of the elastomeric material is at least 90 percent of that of the width of at least one of the non-woven fabrics first and second.

14. The method as claimed in clauses 11, 12 or 13 characterized in that the core layer of the elastomeric material is an elastomeric film fabric core layer.

15. The method as claimed in clause 14 characterized in that the core layer width of elastomeric film fabric is at least 90% of that of the width of at least one of the non-woven fabrics first and second.

16. The method as claimed in clauses 14 or 15 characterized in that the elastomeric film fabric core layer is superimposed on the elastomeric film web fabric.

17. The method as claimed in clauses 14, 15 and 16 characterized in that the joining of the core layer of the elastomeric material to at least one of the first and second non-woven fabrics comprises fusing the core layer of the film fabric elastomeric to said at least one of the first and second non-woven fabrics.

18. The method as claimed in clause 17 characterized in that the elastomeric film fabric core layer is bonded to said at least the first and second nonwoven fabrics only by melting without the use of adhesive.

19. The method as claimed in clause 18 characterized in that the elastomeric film fabric core layer is bonded to both the first and second nonwoven by fusion only, without the use of adhesive.

20. The method as claimed in any one of clauses 14-19 characterized in that the elastomeric web fabric comprises an integrally formed and over-bent portion of the core layer of elastomeric film fabric. SUMMARY A method for forming an elastomeric laminate having specific elastic properties for use in personal care articles is described. In particular embodiments, the method comprises providing the first and second nonwoven fabrics; providing a core layer of the elastomeric material under tension; sandwiching the core layer between the first and second nonwoven fabrics; attaching the core layer to at least one of the first and second non-woven fabrics; providing an elastomeric film tape fabric under tension; sandwiching the elastomeric film web between the first and second non-woven fabrics; and fusing the elastomeric film web fabric to the first and second nonwoven fabrics. In particular embodiments, the core layer of elastomeric material is an elastomeric film fabric core layer. In particular embodiments, the elastomeric film web fabric, the core layer, or both are / are joined to the first and second non-woven fabrics only by melting, without the use of adhesive.